WF-100 Wire Flattener

Overview

The WF-100 Wire Flattener is a powerful, self-contained unit that can be installed with any existing winding machine and used in-line with a coil winding machine to flatten round copper or aluminum wire. The stand-alone system requires no connections to the winder or wire dereeler. A dancer control coordinates the wire flattening speed to the wire winding speed and provides consistent wire tension, and the dancer carriage accumulates wire to reduce negative effects from high speed winding on rectangular coils. The unit is motor driven to keep up with high winding speeds and is built with heavy-duty welded steel construction. Wire Range Handled: 16 AWG (0.0524\" [1.33 mm]) to 5 AWG (0.1848\" [4.69 mm]); Flattening Range: 0.030\" (0.76 mm) to 0.165\" (4.19 mm); Wire Processing Speed: Variable up to 1,500 ft/min. (7.62 m/sec); Drive System: Up to 20 hp (11.19 kW) AC Motor; Electrical input: 460 volts, three phase, 30amps (Other voltages available); Air: 80 PSI (5.5 bars); Weight: 1,100 lbs. (498.95 kg). Standard features include quick and easy flattening size adjustment, fine adjustment for precise sizing, maintenance of consistent wire tension, and accommodation of winding machine acceleration and deceleration. Optional add-ons include special input side wire path pulley arrangements, wire breakage output to signal operator or stop wind, other input voltages, and a larger base frame to incorporate two, three, or four complete systems in a common base. Standard warranty provides coverage for 6 months starting from the date of machine delivery; machine support is available at (978) 779-6600. The WF-100 is used in-line with a coil winding machine to flatten round copper or aluminum wire into square or rectangular profiles during winding, eliminating the need for costly shaped conductors and enabling the use of round wire to save on material costs. Its dancer control and dancer carriage coordinate flattening speed with winding speed to maintain consistent tension and to accommodate winding machine acceleration and deceleration at processing speeds up to 1,500 ft/min. (7.62 m/sec). Most small to medium diameter film coated magnet wire can be flattened to approximately 60% of its original thickness without harming the insulation, and that percentage increases as the wire approaches 8 AWG and larger.